U.S. patent number 8,916,015 [Application Number 13/333,311] was granted by the patent office on 2014-12-23 for tampon method of manufacture.
This patent grant is currently assigned to Kimberly-Clark Worldwide, Inc.. The grantee listed for this patent is John David Amundson, Steven Craig Gehling, Mary Lou McDaniel. Invention is credited to John David Amundson, Steven Craig Gehling, Mary Lou McDaniel.
United States Patent |
8,916,015 |
McDaniel , et al. |
December 23, 2014 |
Tampon method of manufacture
Abstract
A pledget for a tampon having improved leakage prevention of
bodily fluid after the tampon is inserted in the vagina. A method
of manufacturing the pledget can include a step of bringing a
contact member into communication with a fibrous material. The
method can include a step of compressing the fibrous material into
a pledget for a tampon.
Inventors: |
McDaniel; Mary Lou (Appleton,
WI), Amundson; John David (Greenville, WI), Gehling;
Steven Craig (Oshkosh, WI) |
Applicant: |
Name |
City |
State |
Country |
Type |
McDaniel; Mary Lou
Amundson; John David
Gehling; Steven Craig |
Appleton
Greenville
Oshkosh |
WI
WI
WI |
US
US
US |
|
|
Assignee: |
Kimberly-Clark Worldwide, Inc.
(Neenah, WI)
|
Family
ID: |
48653162 |
Appl.
No.: |
13/333,311 |
Filed: |
December 21, 2011 |
Prior Publication Data
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|
|
|
Document
Identifier |
Publication Date |
|
US 20130160259 A1 |
Jun 27, 2013 |
|
Current U.S.
Class: |
156/252;
604/385.17; 156/269 |
Current CPC
Class: |
A61F
13/2034 (20130101); A61F 13/2094 (20130101); A61F
13/2022 (20130101); A61F 13/2088 (20130101); A61F
13/2065 (20130101); A61F 13/2031 (20130101); A61F
13/2068 (20130101); A61F 13/2091 (20130101); Y10T
156/1056 (20150115); Y10T 156/1084 (20150115) |
Current International
Class: |
A61F
13/22 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0 685 213 |
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Dec 1995 |
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EP |
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WO 95/16423 |
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Jun 1995 |
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WO |
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WO 2006/016933 |
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Feb 2006 |
|
WO |
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WO 2010117309 |
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Oct 2010 |
|
WO |
|
Other References
Co-pending U.S. Appl. No. 13/333,150, filed Dec. 21, 2011, by Mary
Lou McDaniel for "Tampon. ". cited by applicant.
|
Primary Examiner: Musser; Barbara J
Attorney, Agent or Firm: Kimberly-Clark Worldwide, Inc.
Claims
What is claimed is:
1. A method of manufacturing a tampon, the method comprising the
steps of: a. providing a fibrous material; b. providing a cover; c.
providing a contact member comprising a first edge and a second
edge; d. incorporating at least two slits in the contact member to
form a contact element in the contact member; e. bonding one of the
first edge or the second edge of the contact member to the cover to
create a bonded edge and a free edge; f. bonding the combination of
the cover and the contact member to the fibrous material; and g.
compressing the combination of the fibrous material, the cover and
the contact member.
2. The method of claim 1 further comprising the step of separating
at least one individual unit from the fibrous material.
3. The method of claim 1 further comprising the step of rolling,
stacking or folding the fibrous material.
4. The method of claim 1 wherein the fibrous material is one of a
nonwoven ribbon, a fleece, and a blank.
5. The method of claim 1 further comprising the step of enclosing
the contact member in an outer sheath.
6. The method of claim 5 further comprising the step of
incorporating at least two slits in the outer sheath.
7. A method of manufacturing a cover for a tampon, the method
comprising the steps of: a. providing a cover ribbon; b. providing
a contact member comprising a first edge and a second edge; c.
incorporating at least two slits into the contact member to form a
contact element; d. bonding one of the first edge or the second
edge of the contact member to the cover ribbon to create a combined
unit of cover ribbon and contact member with a bonded edge and a
free edge; and e. separating the combined unit of cover ribbon and
contact member from a remainder of the cover ribbon.
8. The method of claim 7 further comprising the step of enclosing
the contact member in an outer sheath.
Description
BACKGROUND
Currently, there are two basic types of tampons used for feminine
hygiene. The first type is a digitally insertable tampon which is
designed to be inserted directly by the user's fingers. The second
type is an applicator style tampon which is designed to be inserted
with the aid of an applicator. Both types are usually made by
folding or rolling one or more loosely associated rectangular
strips of absorbent material into a blank and then compressing the
blank into a cylindrically-shaped pledget. The pledget may or may
not have a cover. In both types, a withdrawal string can be
attached to the pledget. The combination of a pledget and a
withdrawal string is considered a useable tampon product. The
tampon can then be wrapped and packaged for sale. In the applicator
style tampon, the tampons can be assembled into an applicator prior
to being wrapped and packaged.
Tampons work by acquiring the vaginal fluids including menses where
the outside surface of the tampon and vaginal wall contact. To
ensure this contact, current tampons alter the vagina immediately
upon insertion. This alteration contributes to early premature,
"by-pass" leakage. After the tampon absorbs the vaginal fluids
including menses, most tampons begin to expand uniformly and
globally, further contributing to this leakage. At the same time,
the tampon begins to become more flexible and conformable to allow
better global/macro fit to the vagina. This predetermined and
uniform tampon response that drives this global/macro expansion is
governed by the tampon construction and materials.
Even when fluid is acquired locally and the deformational forces on
the tampon by the vaginal environment are applied locally with
current tampons, the construction or materials of the tampons
inhibits or constrains their capacity to expand or adapt to give
this local/micro fit. These constructions and materials force the
entire tampon to respond to these local fluid acquisition and
deformational forces through material connectivity or material
stiffness.
When attempts are made to allow for more local adaptation in tampon
constructions, their constructions do not acquire the fluids well
because of inadequate contact area because they can't match the
local contours of the vaginal wall or are not conformable enough to
adapt to the women's individual local contours (e.g. folds and
convolutions) found on the vaginal wall. In addition, these
attempts create integrity issues with the tampons that lead to
portions of the tampon remaining within the vagina after tampon
removal. This inadequate contact is especially true during the
wiping action of the vagina by the tampon when the tampon is
inserted and removed.
Current tampon construction processes construct these inadequate
tampons that have this predetermined and uniform tampon response.
They create these constraints, inadequate contact area, and
integrity issues in order to drive this predetermined and uniform
tampon response and, therefore, limit the tampon from effectively
responding locally. New construction processes will be needed to
construct tampons that overcome the inadequacy of current
tampons.
There remains a need for a tampon that responds locally to meet the
individual protection needs of women and processes to make such
tampons. There remains a need for a tampon that prevents leakage of
body fluid after being inserted into a woman's vagina. There
remains a need for a tampon that provides efficient utilization of
the entire tampon structure during use. There remains a need for a
tampon that provides a customized fit to the anatomy of a woman's
vaginal cavity. There remains a need for a tampon that can deform
and come into contact with the folds and convolutions of the walls
of the vaginal cavity and acquire any contacted fluid.
SUMMARY
In an embodiment a method of manufacturing a pledget has the steps
of providing a fibrous material, providing a contact member,
incorporating at least two slits in the contact member to form a
contact element in the contact member, bonding the contact member
to the fibrous material, and compressing the combination of the
fibrous material and the contact member. In an embodiment, the
method further has the step of separating at least one individual
unit from the fibrous material. In an embodiment, the method
further has the step of rolling, stacking or folding the fibrous
material. In an embodiment, the fibrous material is one of a
nonwoven ribbon, a fleece, and a blank. In an embodiment, the
method further has the step of providing a cover. In an embodiment,
the method further has the step of bonding the contact member to
the cover. In an embodiment, the contact member has a first edge
and a second edge and the step of bonding the contact member to the
fibrous material further has the step of bonding one of the first
edge or the second edge to the fibrous material creating a bonded
edge and a free edge. In an embodiment, the method further has the
step of enclosing the contact member in an outer sheath. In an
embodiment, the method further has the step of incorporating at
least two slits in the outer sheath.
In an embodiment, a method of manufacturing a tampon has the steps
of providing a fibrous material, providing a cover, providing a
contact member, incorporating at least two slits in the contact
member to form a contact element in the contact member, bonding the
contact member to the cover, bonding the combination of the cover
and the contact member to the fibrous material, and compressing the
combination of the fibrous material, the cover and the contact
member. In an embodiment, the method further has the step of
separating at least one individual unit from the fibrous material.
In an embodiment, the method further has the step of rolling,
stacking or folding the fibrous material. In an embodiment, the
fibrous material is one of a nonwoven ribbon, a fleece, and a
blank. In an embodiment, the contact member has a first edge and a
second edge and the step of bonding the contact member to the cover
further has the step of bonding one of the first edge or the second
edge to the cover to create a bonded edge and a free edge. In an
embodiment, the method further has the step of enclosing the
contact member in an outer sheath. In an embodiment, the method
further has the step of incorporating at least two slits in the
outer sheath.
In an embodiment, a method of manufacturing a cover has the steps
of providing a cover ribbon, providing a contact member comprising
a first edge and a second edge, bonding one of the first edge or
the second edge of the contact member to the cover ribbon to create
a combined unit of cover ribbon and contact member, and separating
the combined unit of cover ribbon and contact member from a
remainder of the cover ribbon. In an embodiment, the method further
has the step of enclosing the contact member in an outer sheath. In
an embodiment, the method further has the step of incorporating at
least two slits into the contact member to form a contact
element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of a tampon.
FIG. 2 is a perspective view of an embodiment in which a cover is
bonded to a nonwoven ribbon.
FIG. 3 is a perspective view of an embodiment in which a cover is
bonded to a fleece.
FIG. 4 is a top view of an embodiment in which a cover is bonded to
a fleece.
FIG. 5 is a perspective view of an embodiment in which a cover is
bonded to a blank, such as a blank formed by radial winding of a
fleece.
FIG. 6A is an end view of an embodiment in which a cover is bonded
to a blank, such as a blank formed by compression of a fleece.
FIG. 6B is an end view of an embodiment in which two covers are
bonded to a blank, such as a blank formed by compression of a
fleece.
FIG. 7 is a side view of an embodiment of a tampon wherein the
cover defines a skirt.
FIG. 8 is a perspective view of an embodiment of a contact member
in communication with a cover.
FIG. 9A-9E are top views of slits incorporated into a contact
member in a flat, unfolded configuration.
FIG. 10A-10C are perspective views of slits incorporated into a
contact member in a folded configuration.
FIG. 11 is a perspective view of an embodiment of a tampon.
FIG. 12 is a perspective view of an embodiment of a tampon.
FIG. 13 is a perspective view of an embodiment of a tampon.
FIG. 14 is a side view of an embodiment of two contact members in
communication with a cover.
FIG. 15A is a perspective view of an embodiment of a contact member
with a single fold and in communication with a cover.
FIG. 15B is a side view of an embodiment of a contact member with a
fold and in communication with a cover.
FIG. 16 is a perspective view of an embodiment of a contact member
with two folds and in communication with a cover.
FIG. 17 is a side view of an embodiment of a contact member with an
outer sheath and in communication with a cover.
FIG. 18 is a perspective view of an embodiment of a method of
bonding an outer sheath to a contact member.
FIG. 19 is a perspective view of an embodiment of a method of
bonding a contact member enclosed by an outer sheath to a
cover.
FIG. 20 is a perspective view of an embodiment of a tampon in which
the cover is a contact member.
DETAILED DESCRIPTION
The tampon of the current disclosure is designed to be inserted
above the introital region of a woman's vagina and is designed to
function so as to intercept the fluid flow of menses, blood, and
other body fluids and prevent the fluid from exiting the vagina.
While the pledgets and tampons of the current disclosure are
described for use as a menstrual device, it will be readily
apparent that the pledgets and tampons can also be used as any
other suitable vaginal insert, such as a pessary. Likewise, while
the pledgets and tampons of the current disclosure are generally
described as being "absorbent," it will be readily apparent that
the pledgets and tampons may be coated or otherwise treated to be
partially or completely non-absorbent. The pledget and tampon of
the current disclosure can have a contact member which can have a
contact element. In an embodiment, the contact element can be small
and can be created by slitting flexible materials which can allow
the pledget and the tampon to respond locally to the changes in the
vaginal environment and can effectively acquire fluid locally to
accommodate the uniqueness of a woman's vaginal environment and her
period.
An embodiment of a tampon 10 of the current disclosure is
illustrated in FIG. 1. The tampon 10 is designed to be inserted
into a woman's vaginal cavity to prevent menses from exiting the
vaginal opening by contacting and absorbing the flow of menses. The
term "menses," as used herein, includes blood, tissue debris, and
other bodily fluids emitted from the vaginal opening. The tampon 10
can have a compressed, generally cylindrical shaped pledget 12 and
a withdrawal aid 14. In some embodiments, the generally cylindrical
shape of the pledget 12 can have a cross-section that is at least
one of an oval, circle, square, rectangle, or any other
cross-sectional shape known in the art. The term "cross-section"
refers herein to the plane which extends laterally through the
tampon 10, and which is orthogonal to the longitudinal axis 16 of
the pledget 12, and consequently, of the tampon 10. The tampon 10
can have an insertion end 18 and a withdrawal end 20. The tampon 10
can have a length 22 wherein the length 22 is the measurement of
the tampon 10 along the longitudinal axis 16 originating at one end
(insertion or withdrawal) of the tampon 10 and ending at the
opposite end (insertion or withdrawal) of the tampon 10. In some
embodiments, the tampon 10 can have a length 22 from about 30 to
about 60 mm. The tampon 10 can have a width 24, which unless
otherwise stated herein, can correspond to the greatest
cross-sectional dimension along the longitudinal axis 16 of the
tampon 10. In some embodiments, the tampon 10 can have a compressed
width 24 prior to usage from about 2, 5, or 8 to about 20 or 30 mm.
The tampon 10 may be straight or non-linear in shape, such as
curved along the longitudinal axis 16.
As noted above, the tampon 10 can have a pledget 12. The pledget 12
can have an absorbent core 26 which can be formed from a blank 28,
such as a softwind, wherein the blank 28 can be formed from a
fleece 30. The fleece 30 can be formed from a nonwoven ribbon 32
composed of fibrous materials 138. It is to be understood, that
each of the nonwoven ribbon 32, the fleece 30, the blank 28, the
absorbent core 26, the pledget 12 can be formed from fibrous
material 138. The fleece 30 can be any size and thickness that can
ultimately be compressed into a pledget 12 having a vaginally
insertable shape. In an embodiment, the fleece 30 can be a laminar
structure that can have individual distinct layers of absorbent
material. In an embodiment in which the fleece 30 has a laminar
structure, the layers can be formed from a single absorbent
material and/or from different absorbent materials. In an
embodiment, the size of the fleece 30 can range from about 40 mm to
about 100, 200, 250 or 300 mm in length and from about 40 mm to
about 80 mm in width. In an embodiment, the overall basis weight of
the fleece 30 can range from about 15, 20, 25, 50, 75, 90, 100,
110, 120, 135 or 150 gsm to about 1,000, 1,100, 1,200, 1,300,
1,400, or 1,500 gsm.
The fleece 30, and consequently, the pledget 12 of the tampon 10,
may be constructed from a nonwoven ribbon 32 of absorbent materials
such as fibrous materials 138. Such absorbent materials can
include, but are not limited to, natural and synthetic fibers such
as, but not limited to, polyester, acetate, nylon, cellulosic
fibers such as wood pulp, cotton, rayon, viscose, LYOCELL.RTM. such
as from Lenzing Company of Austria, or mixtures of these or other
cellulosic fibers. Natural fibers can include, but are not limited
to, wool, cotton, flax, hemp and wood pulp. Wood pulps can include,
but are not limited to, standard softwood fluffing grade such as
CR-1654 (US Alliance Pulp Mills, Coosa, Ala.). Pulp may be modified
in order to enhance the inherent characteristics of the fibers and
their processability. Crimping can be imparted to the fibers by any
means deemed suitable by one of ordinary skill Curl may be imparted
to the fibers by suitable methods such as, for example, chemical
treatment or mechanical twisting. Curl can be imparted before
crosslinking or stiffening. Pulps may be stiffened by the use of
crosslinking agents such as formaldehyde or its derivatives,
glutaraldehyde, epichlorohydrin, methylated compounds such as urea
or urea derivatives, dialdehydes such as maleic anhydride,
non-methylated urea derivatives, citric acid or other
polycarboxylic acids. Pulp may also be stiffened by the use of heat
or caustic treatments such as mercerization. Examples of these
types of fibers include NHB416, which is a chemically cross-linked
southern softwood pulp fiber which enhances wet modulus, available
from Weyerhaeuser Corporation of Tacoma, Wash. Other non-limiting
examples of useful pulps are debonded pulp (NF405) and non-debonded
pulp (NB416) also from Weyerhaeuser. HPZ3 from Buckeye
Technologies, Inc. of Memphis, Tenn., is an example of a fiber that
has a chemical treatment that sets in a curl and twist, in addition
to imparting added dry and wet stiffness and resilience to the
fiber. Another suitable pulp is Buckeye HP2 pulp and still another
is IP Supersoft from International Paper Corporation. The absorbent
materials can include any suitable blend of fibers. For example,
the absorbent fibers can be formed from cellulose fibers such as
cotton and rayon. The absorbent fibers can be 100 wt % cotton, 100
wt % rayon, or a blend of cotton and rayon. In some embodiments,
the cellulose fibers may be modified for super-absorbency.
In an embodiment, the fibers can have a staple length of from about
5, 10, 15 or 20 mm to about 30, 40 or 50 mm. In an embodiment, the
fibers can have a fiber size of from about 15 microns to about 28
microns. In an embodiment, the fibers can have a denier of from
about 1 or 2 to about 6. Denier is a unit of fineness of yarn based
on a standard of 50 milligrams (mg) for 450 meters of yarn. The
fibers can have a circular, bi-lobal or tri-lobal cross-sectional
configuration or any other configuration known to those skilled in
the art. A bi-lobal configuration can have a cross-sectional
profile which can look like a dog bone while a tri-lobal
configuration can have a cross-sectional profile which can look
like a "Y." In an embodiment, the fibers can be bleached. In an
embodiment, the fibers can have a color.
In an embodiment, the nonwoven ribbon 32 can contain fibers such as
binder fibers. In an embodiment, the binder fibers can have a fiber
component which will bond or fuse to other fibers in the nonwoven
ribbon 32. Binder fibers can be natural fibers or synthetic fibers.
Synthetic fibers include, but are not limited to, those made from
polyolefins, polyamides, polyesters, rayon, acrylics, viscose,
superabsorbents, LYOCELL.RTM. regenerated cellulose and any other
suitable synthetic fiber known to those skilled in the art.
Non-limiting examples of polyolefins include, but are not limited
to, polyethylene such as Dow Chemical's ASPUN.RTM. 681 1A linear
low density polyethylene, 2553 LLDPE and 25355 and 12350 high
density polyethylene. The polyethylenes can have melt flow rates,
respectively, of about 26, 40, 25, and 12. Non-limiting examples of
fiber forming polypropylenes include, but are not limited to, Exxon
Chemical Company's ESCORENE.RTM. PD 3445 polypropylene and Montell
Chemical Company's PF304. Another example of a fiber can be a
bi-component polyester sheath and polyethylene core known as T255
made by Trevira of Germany. Other non-limiting examples of meltable
bicomponent fibers include, but are not limited to, fibers
available from Unitika of Japan, such as, for example, Unitika
MELTY 4080, and 6080 fibers, having either polyester sheaths or
cores and polyethylene sheaths or cores. Another example includes,
but is not limited to, fibers available from Fibervisions under the
designation ETC Bounce fiber line, such as PET/PE fibers of about
2.2 decitex and about 40 mm staple fiber length. Non-limiting
examples of rayon fibers include 1.5 denier Merge 18453 fibers from
Accordis Cellulose Fibers Inc. of Axis, Ala. The fibers can be
treated by conventional compositions and/or processes to enable or
enhance wettability.
Various methods known to those skilled in the art can be used to
prepare the nonwoven ribbon 32. Such methods can include, but are
not limited to, airlaying, carding, wetlaying, needlepunching,
mechanical entanglement, hydroentangling, and any other known
method deemed suitable by one of ordinary skill. In an embodiment,
a bonded carded web can be made from staple fibers. In such an
embodiment, the fibers can be longer than about 20, 30 or 35 mm.
The fibers can be purchased in bales which can be placed in a
picker to separate the fibers. The fibers can then be sent through
a combing or carding unit, which can further break apart and align
the staple fibers in the machine direction to form a generally
machine direction-oriented fibrous nonwoven web. Once the web is
formed, it can then be bonded by one or more of several known
bonding methods, such as through air bonding or pattern bonding. In
an embodiment, a dry laid web can be made from staple fibers. In
such an embodiment, the fibers can be about 20 mm or longer. In dry
laying, fibers or tufts of fibers of a first type (e.g., absorbent
fibers and/or binder fibers) can be fed to a first rotating vacuum
drum and fibers or tufts of fibers of a second type (e.g.,
absorbent fibers and/or binder fibers) can be fed to a second
rotating vacuum drum. The fibers can then be laid down by suction
to form mats of fibers. The mats of fibers can be doffed from the
vacuum drums and combed via rotating lickerins. The lickerins can
have peripheral teeth which can comb the fibers from the mat. The
combed fibers can be doffed from the lickerins via centrifugal
force and placed into a fiber mixing and expansion chamber. The
mixed fibers can be placed on a vacuum screen to form a random
fiber web comprising the first and second fiber types. The flow and
velocity of each independent fiber stream can be controlled to
provide the desired quantity of each fiber type.
In an embodiment in which binder fibers are present, the binder
fibers can be activated to create a three-dimensional fiber matrix.
In such an embodiment, the activation can be completed by any
suitable heating step including, but not limited to, convection
heating, through air heating, superheated steam, microwave heating,
radiant heating, radio frequency heating, and the like, and
combinations thereof. In some embodiments, the activation can be
accomplished by heating the nonwoven ribbon 32 at a temperature of
from about 240.degree. F. to about 330.degree. F. (about 115 to
about 165.degree. C.) to activate the binder fibers. It is to be
understood that the bonding temperature selected should be selected
based upon the materials which are being bonded together. Without
being bound by theory, it is believed that during activation, the
binder fibers can soften and become tacky and, therefore, bind to
adjacent fibers creating a three-dimensional fiber matrix. It is
believed that the three-dimensional fiber matrix can stabilize the
nonwoven ribbon 32 and can create a liquid stable network. It is to
be understood that an additional component or finish can be added
to the fibers to facilitate bonding of absorbent materials which
are not necessarily compatible.
In an embodiment, the activation can be followed by a cooling step
which can utilize any suitable means for reducing the temperature
of the nonwoven ribbon 32. In an embodiment, the nonwoven ribbon 32
can be cooled by allowing the nonwoven ribbon 32 to return to
ambient temperature over a period of time. In an embodiment, the
nonwoven ribbon 32 can be cooled by chill rolls, cooling chambers,
blowing conditioned air, or the like, and combinations thereof. In
an embodiment, the cooling step can occur prior to compression of
the nonwoven ribbon 32 to establish a wet-stable three-dimensional
structure.
In some embodiments, the nonwoven ribbon 32 can be further
manipulated such as, for example, being folded, corrugated, or
otherwise processed. The nonwoven ribbon 32 can be separated into
individual units of fleece 30. The separation of the nonwoven
ribbon 32 into individual units of fleece 30 can occur by any
suitable method such as stretching, perforating, cutting such as
with the use of a die cutter or a knife cutter, and the like. The
individual units of fleece 30 can then be rolled, stacked, folded,
or otherwise manipulated into blanks 28 before compressing the
blanks 28 into pledgets 12.
In various embodiments, the fleece 30 and the resultant pledget 12
can have any suitable combination and ratio of fibers. In an
embodiment, the fleece 30 and the resultant pledget 12 can include
from about 70 to about 95 wt % absorbent fibers and from about 5 to
about 30 wt % binder fibers. In an embodiment, the fleece 30 and
the resultant pledget 12 can include from about 80 to about 90 wt %
absorbent fibers and from about 10 to about 20 wt % binder fibers.
In an embodiment, the fleece 30 and the resultant pledget 12 can
include about 85 wt % absorbent fibers and about 15 wt % binder
fibers. In an embodiment, the fleece 30 and the resultant pledget
12 can include from about 80 to about 90 wt % trilobal viscose
rayon fibers and from about 10 to about 20 wt % bicomponent binder
fibers. In an embodiment, the fleece 30 and the resultant pledget
12 can include 85 wt % trilobal viscose rayon fibers and about 15
wt % bicomponent binder fibers. In an embodiment, the fleece 30 and
the resultant pledget 12 can include greater than about 70, 80, 90,
95, 97, or 99 wt % absorbent fibers.
With reference to FIGS. 2-6, in various embodiments, a cover 34 can
be provided. As used herein, the term "cover" relates to materials
that are in communication with and cover or enclose surfaces, such
as, for example, a body facing surface 36, an interior surface 38,
or combination thereof, of an absorbent core 26 of the resultant
pledget 12 and reduce the ability of portions (e.g., fibers and the
like) from becoming separated from the pledget 12 or the tampon 10
and being left behind upon removal of the tampon 10 from the
woman's vagina. In various embodiments, the cover 34 can be a
fluid-permeable cover 34. By "fluid-permeable" it is meant that
body fluid is able to pass through the cover 34. The cover 34 can
be hydrophobic or hydrophilic. By "hydrophilic" it is meant that
the cover 34 has an affinity for absorbing or tending to combine
with water. By "hydrophobic" it is meant that the cover 34 is
antagonistic to or tending not to combine with water. The cover 34
can also be treated with a surfactant or other material to make it
hydrophilic or to make it more hydrophilic.
As will be described herein, the cover 34 can be bonded with: the
nonwoven ribbon 32 prior to separation into individual units of
fleece 30 (as illustrated in FIG. 2), an individual unit of fleece
30 (as illustrated in FIGS. 3 and 4), a blank 28 which has been
formed from a fleece 30 (as illustrated in FIGS. 5, 6A and 6B), or
to the pledget 12 following compression of the blank 28. In an
embodiment in which the cover 34 is bonded with a pledget 12
following compression of a blank 28, the cover 34 can be extensible
such that the tampon 10 can expand within the vaginal cavity.
The cover 34 can, therefore, be bonded to the nonwoven ribbon 32, a
fleece 30, a blank 28, or the resultant pledget 12. The terms
"bonded" or "bonding" refer herein to the joining, adhering,
connecting, attaching or the like of two elements. Two elements
will be considered bonded together when they are bonded directly to
one another or indirectly to one another, such as when each is
directly bonded to intermediate elements. The bonding can occur by
any method deemed suitable including, but not limited to,
adhesives, ultrasonic bonds, thermal bonds, pressure bonds,
mechanical entanglement, hydroentanglement, microwave bonds, or any
other conventional technique. The bonding can extend continuously
along the length of bonding, or it may be applied in an
intermittent fashion at discrete intervals.
In various embodiments, the cover 34 can be formed from nonwoven
materials or apertured films. The nonwoven materials can include,
but are not limited to, materials such as natural fibers, synthetic
fibers, or blends of natural and synthetic fibers. Natural fibers
include, but are not limited to, rayon, cotton, wood pulp, flax,
and hemp. Synthetic fibers can include, but are not limited to,
fibers such as polyester, polyolefin, nylon, polypropylene,
polyethylene, polyacrylic, vinyl polyacetate, polyacrylate,
cellulose acetate, or bicomponent fibers, such as bicomponent
polyethylene and polypropylene fibers. The cover 34 can be made by
any number of suitable techniques such as, for example, being
spunbond, carded, hydroentangled, thermally bonded, and resin
bonded. In an embodiment, the cover 34 can be formed from an
apertured thermoplastic film having either a two-dimensional or a
three-dimensional thickness.
In an embodiment, the cover 34 can be a 12 gsm smooth calendared
material made from bicomponent, polyester sheath and polyethylene
core, fibers such as Sawabond 4189 available from Sandler AG,
Schwarzenbach, Germany. In an embodiment, the cover 34 can be
formed from a single piece of material. In an embodiment, the cover
34 can be formed from multiple discrete pieces of material which
are bonded together. In an embodiment, the cover 34 can be
bleached. In an embodiment, the cover 34 can have a color.
In an embodiment, the cover 34 can be treated with an aqueous
solution to reduce frictional drag, to give the tampon 10 a
permanent wettability, to enhance the ease of insertion into and
withdrawal from a woman's vagina, and combinations thereof. In an
embodiment, the cover 34 can be treated either before being rolled
or folded up with the fleece 30 into a blank 28 or after the blank
28 has been formed and the cover 34 has been bonded with the blank
28.
As illustrated in FIG. 5, in an embodiment, at least a portion of
the cover 34 can cover a portion of the body facing surface 36 of a
blank 28 and the resultant absorbent core 26 of a pledget 12. As
illustrated in FIG. 6A, in an embodiment, at least a portion of the
cover 34 can cover a portion of an interior surface 38 of a blank
28 and the resultant absorbent core 26 of the a pledget 12 when a
fleece 30 is compressed, such as, for example, via side
compression. As illustrated in FIG. 6A, in an embodiment, at least
a portion of the cover 34 can cover a combination of the body
facing surface 36 and the interior surface 38 of a blank 28 and the
resultant absorbent core 26 of a pledget 12. The interior surface
38 of the blank 28 and of the resultant absorbent core 26 of a
pledget 12 can result from folding, rolling, or otherwise
manipulating the fleece 30 into the blank 28. It is to be
understood that in an embodiment, the interior surface 38 of the
absorbent core 26 of the pledget 12 may come into contact with the
vaginal walls as the tampon 10 can expand when contacted by body
fluids. The expansion of the tampon 10 can, therefore, cause
exposure of the interior surface 38 of the pledget 12 to the
vaginal walls and body fluid. As illustrated in FIG. 6B, in an
embodiment two covers 34 can be in communication with a fleece 30
which can be compressed, such as, for example, via side
compression, into a blank 28. As illustrated in FIG. 6B, in such an
embodiment, at least a portion of each of the covers 34 can cover a
portion of an interior surface 38 of a blank 28 and the resultant
absorbent core 26 of a pledget 12. In such an embodiment, at least
a portion of each of the covers 34 can cover a combination of the
body facing surface 36 and the interior surface 38 of a blank 28
and the resultant absorbent core 26 of a pledget 12. In various
embodiments, the cover 34 can extend beyond the withdrawal end 20
of the pledget 12 to form a skirt 40 as illustrated in FIG. 7. It
is to be understood that, in an embodiment, the cover 34 can extend
beyond the insertion end 18 of the pledget 12.
In an embodiment, the cover 34 can have two edges, 42 and 44. As
noted above, the cover 34 can be bonded to a nonwoven ribbon 32, a
fleece 30, a blank 28, or a pledget 12. In an embodiment, during
the bonding process, at least one of the edges, 42 or 44, of the
cover 34 can be substantially aligned with one edge of the nonwoven
ribbon 32 (such as edge 46), one edge of the fleece 30 (such as
edge 48), or one edge of the blank 28 (such as edge 50). In an
embodiment, during the bonding process, the cover 34 can be bonded
to the nonwoven ribbon 32, the fleece 30, the blank 28, or the
pledget 12 so as to produce a spiral or helical pattern on the
resulting pledget 12. As illustrated in non-limiting examples, such
as in FIGS. 3-5, the two edges, 42 and 44, are illustrated in a
direction that would be perpendicular to the longitudinal axis 16
of a resultant absorbent core 26 of a pledget 12. It is to be
understood that the edges, 42 and 44, can also be positioned in a
direction parallel to the longitudinal axis 16 of a resultant
absorbent core 26 of a pledget 12 or at any other angle to the
longitudinal axis 16 of an absorbent core 26 of a pledget 12 such
as may occur if the cover 34 is spirally wound about the absorbent
core 26 of a pledget 12. Thus, while the cover 34 and the edges, 42
and 44, may be discussed herein in an orientation perpendicular to
the longitudinal axis 16 of an absorbent core 26 of a pledget 12,
one of ordinary skill will be able to recognize how to provide a
cover 34 and edges, 42 and 44, in an orientation parallel with the
longitudinal axis 16 of an absorbent core 26 of a pledget 12 or in
an orientation having any other angle in relation to the
longitudinal axis 16 of an absorbent core 26 of a pledget 12.
In an embodiment, the cover 34 can have uniform properties. In an
embodiment, the cover 34 can have non-uniform properties. In such
an embodiment, the cover 34 can have regions with differing
properties which can be coordinated to increase or decrease
absorbency and/or level of expansion of the tampon 10. For example,
a region can be more hydrophilic or hydrophobic in comparison to
another region of the cover 34. In an embodiment, the hydrophilic
region of the cover 34 could substantially cover the portion of the
tampon 10 that would contact the menses first to increase menses
absorption and as a result increase expansion of that portion of
the tampon 10.
The regions of the cover 34 with differing properties may be
produced by various methods. One example of a method is by treating
the regions of the cover 34 with chemical finishes, such as
hydrophilic or hydrophobic finishes that make the regions either
more hydrophilic or more hydrophobic, respectively. The regions can
also be mechanically altered. Any method known in the art of
mechanically altering non-wovens or films can be used to provide a
cover 34. Mechanically altering includes, but is not limited to,
processes such as ring-rolling, corrugating, SELFing, and
aperturing.
The composition of the cover 34 can also provide for differing
properties of the cover 34. Different regions of the cover 34 can
be produced from different materials. For example, one region of
the cover 34 may have a higher concentration of rayon than another
section of the cover 34 to make that region more hydrophilic.
Materials could be selected for any property desired for a cover 34
known in the art, such as a selection of a material to provide a
region of the cover 34 with greater extensibility. In an
embodiment, the cover 34 may include multiple discrete pieces that
are bonded together to form a single cover 34. The discrete pieces
can have differing properties such as described above. In an
embodiment, the discrete pieces of the cover 34 may form the
different regions of the cover 34 such as described above. In such
an embodiment, one discrete piece may form one region and another
discrete piece may form a different region of the cover 34. The
discrete pieces can be bonded by any method known to one of
ordinary skill in the art, such as sewing, adhesive, thermal
bonding, fusion bonding, or combinations thereof.
FIG. 8 illustrates an embodiment in which a contact member 52 can
be in communication with the cover 34. As will be described herein
and as illustrated in FIG. 17, the contact member 52 can have an
outer sheath 110. The contact member 52 can have at least one
contact element 54. Without being bound by theory, it is believed
that when the tampon 10 is in use the contact element 54 can at
least partially expand outwardly from the tampon 10 when contacted
by bodily fluids. It is believed that such expansion of the contact
element 54 can reduce or prevent leakage of bodily fluids from the
woman's vagina.
In various embodiments, the contact member 52 can be a
fluid-permeable contact member 52. The contact member 52 can be
hydrophobic or hydrophilic. The contact member 52 can also be
treated with a surfactant or other material to make it hydrophilic
or to make it more hydrophilic.
The contact member 52 can be formed from nonwoven materials or
apertured films. The nonwoven materials can include, but are not
limited to, materials such as natural fibers, synthetic fibers, or
blends of natural and synthetic fibers. Natural fibers include, but
are not limited to, rayon, cotton, wood pulp, flax, and hemp.
Synthetic fibers can include, but are not limited to, fibers such
as polyester, polyolefin, nylon, polypropylene, polyethylene,
polyacrylic, vinyl polyacetate, polyacrylate, cellulose acetate, or
bicomponent fibers, such as bicomponent polyethylene and
polypropylene fibers. Non-limiting examples of other acceptable
materials include creped cellulose wadding, meltblown polymers
including conform, chemically stiffened, modified or cross-linked
cellulosic fibers, synthetic fibers such as crimped polyester
fibers, peat moss, tissue including tissue wraps and tissue
laminates, or any equivalent material or combinations of materials,
or any mixtures of these. In an embodiment, the contact member 52
can be a laminar structure that can have individual distinct layers
of absorbent material, non-absorbent material, moisture insensitive
material, or combinations thereof. In such an embodiment, the
individual distinct layers can be formed from a single material or
from a combination of different materials. The contact member 52
can be made by any number of suitable techniques such as, for
example, being spunbond, carded, hydroentangled, thermally bonded,
and resin bonded. In an embodiment, the contact member 52 can be
formed from an apertured thermoplastic film having either a
two-dimensional or a three-dimensional thickness. In an embodiment,
the contact member 52 can be bleached. In an embodiment, the
contact member 52 can have a color.
In an embodiment, the contact member 52 can be bonded to the cover
34. The contact member 52 can be bonded to the cover 34 prior to or
after the cover 34 is bonded to the nonwoven ribbon 32, the fleece
30, or the blank 28. The contact member 52 can be bonded to the
cover 34 by any method suitable including, but not limited to,
adhesives, ultrasonic bonds, thermal bonds, pressure bonds,
microwave bonds, mechanical entanglement, hydroentanglement, or any
other conventional technique.
In an embodiment, the contact member 52 can have a bonded edge 56,
which can be bonded to the cover 34, and a free edge 58. It is to
be understood that while edge 56 is described herein as a bonded
edge, in an embodiment, both edges, 56 and 58, of the contact
member can be free edges and the bonding of the contact member 52
to the cover 34 can occur at any location of the contact member 52
between the two edges, 56 and 58, as desired. It is to be
understood that while the edges, 56 and 58, are illustrated in the
various figures described herein as straight lines, it is to be
understood that the edges, 56 and 58, can be linear, non-linear,
arcuate, and any combination thereof deemed suitable. In an
embodiment, the bonded edge 56 can have a length 60 which can be
any length deemed suitable to bond the contact member 52 to the
cover 34. In an embodiment, the length 60 can be at least about 1
mm. In an embodiment, the length 60 can be at least about 1, 2, 3,
4, or 5 mm. In an embodiment, the length 60 can be from about 1, 2,
3, 4, or 5 mm to about 6, 7, 8, 9, or 10 mm. The bonding of the
contact member 52 to the cover 34 can be continuous or
intermittent. The bonding of the contact member 52 to the cover 34
can occur across the full width 122 of the cover 34 or any amount
less than the full width 122 of the cover 34. It is to be
understood that the contact member 52 can be bonded to the cover 34
in any manner as deemed suitable. In an embodiment, the contact
member 52 can be located between the cover 34 and the body facing
surface 36 of a resultant absorbent core 26 of a pledget 12. In
such an embodiment, the cover 34 can be slit or offset from the
contact element(s) 54 so as to allow the contact element(s) 54 to
deform and flex away from the absorbent core 26 of the pledget 12.
In an embodiment, the contact member 52 can be separated from the
body facing surface 36 of a resultant absorbent core 26 of a
pledget 12 by a cover 34 such that the contact member 52 and the
contact element(s) 54 can directly contact the walls of the vaginal
cavity.
In an embodiment, the contact member 52 can have at least one
contact element 54. In an embodiment, the contact member 52 can
have at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 contact elements 54.
In an embodiment, the contact member 52 can have from 1, 2, 3, 4,
5, 6, 7, 8, 9, or 10 to 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20
contact elements 54.
In an embodiment, a contact element 54 can be at least partially
separated from another contact element 54 by a slit 62. The slit 62
can be cut through the material of the contact member 52 and can
extend from a first surface 64 of the contact member 52 through to
a second surface 66 of the contact member 52. In an embodiment, the
slit 62 can extend from the free edge 58 of the contact member 52
toward the bonded edge 56 of the contact member 52. In various
embodiments, the slit 62 can extend in a straight line, an arcuate
line, or combinations thereof, from the free edge 58 of the contact
member 52 towards the bonded edge 56 of the contact member 52. In
an embodiment, the slit 62 can extend any length 68 as desired from
the free edge 58 of the contact member 52 toward the bonded edge 56
of the contact member 52. It is to be understood that the slit 62
does not have to extend from the free edge 58 of the contact member
52. It is to be understood that the slit 62 can be located in any
location of the contact member 52 as deemed suitable. The length 68
can be measured as the length 68 between the terminal ends of the
slit 62. In an embodiment in which the slit 62 contains an arc, the
arc length can be determined by any manner deemed suitable by one
of ordinary skill in determining the length 68 of the slit 62. In
various embodiments, the slit length 68 can be equal to, less than,
or greater than the length 82 of the contact member 52 between the
free edge 58 and the bonded edge 56. As a non-limiting example, in
an embodiment, the slit length 68 can be a length 68 longer than
the length 82 between the free edge 58 and the bonded edge 56 of
the contact member 52 as can occur when the slit 62 is cut at an
angle to the free edge 58 or when the slit 62 contains an arc. In
an embodiment in which the slit 62 is cut at an angle to the free
edge 58, the slit length 68 can be longer than the length 82
between the free edge 58 and the bonded edge 56 of the contact
member 52, however, the projected length can be as long as the
length 82 between the free edge 58 and the bonded edge 56 of the
contact member 52. In an embodiment, the slit length 68 can range
from about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm
to about 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or
30 mm. In an embodiment, the slit length 68 can be greater than
about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm.
As noted above, in an embodiment, a contact member 52 can have an
edge, such as edge 56 or 58, which can be linear, non-linear,
arcuate, and any combination thereof as deemed suitable. Such an
edge can be produced in any manner as deemed suitable, such as, but
not limited to, knife cutting, die cutting, or any other method
known to one skilled in the art. In an embodiment, the contact
member 52 can have an edge, such as edge 56 or 58, which can be
arcuate. In such an embodiment, a contact member 52 edge, 56 or 58,
can have an undulating arcuate pattern that can produce discrete
contact elements 54. The amplitude of each arc can be any amplitude
as deemed suitable. In such an embodiment, a contact element 54
can, therefore, be at least partially separated from another
contact element 54 by the amplitude of the arc. It should be
understood that in such an embodiment, a slit 62 need not be
present to form a contact element 54. In such an embodiment, a slit
62 can be used in combination with the amplitude of an arc to
separate one contact element 54 from another contact element
54.
In an embodiment, the contact member 52 can have three regions: a
slit region 70, a bonded region 72, and a free non-slit region 74.
The slit region 70 can be the portion of the contact member 52
containing the slit(s) 62. The bonded region 72 can be the portion
of the contact member 52 containing the bonded edge 56 of the
contact member 52. The free non-slit region 74 can be the portion
of the contact member 52 which is not bonded to the cover 34 and
does not contain any slit(s) 62. In an embodiment, the contact
member 52 can have a slit region 70 having a length 76 from about
1, 2, 3, 4, 5, 6, or 7 mm to about 8, 9, 10, 11, 12, 13, 14, or 15
mm, a bonded region 72 having a length 78 from about 1, 2, 3, 4, or
5 mm to about 6, 7, 8, 9, or 10 mm, and a free non-slit region 74
having a length 80 from about 1, 2, 3, 4, or 5 mm to about 6, 7, 8,
9, or 10 mm. In an embodiment, a contact member 52 can have
multiple bonded regions 72, multiple slit regions 70, multiple free
non-slit regions 74, and combinations thereof.
In an embodiment, the contact member 52 can have at least one slit
62. In an embodiment, the contact member 52 can have at least 1, 2,
3, 4, 5, 6, 7, 8, 9, or 10 slits 62. In an embodiment, the contact
member 52 can have from about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 to
about 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 slits 62. In an
embodiment, the contact member 52 has the appropriate number of
slits 62 to provide the desired number of contact elements 54.
In an embodiment in which the contact member 52 has more than one
slit 62, each slit can have the same length 68. In an embodiment in
which the contact member 52 has more than one slit 62, a slit 62
can have a length 68 that differs from the length 68 of at least
one other slit 62. In an embodiment, at least about 20, 25, 40, 45,
50, 55, 70, 75, 80 or 85% of the slits 62 of the contact member 52
can have substantially the same length 68. In an embodiment, about
50% of the slits can have substantially the same length (e.g., a
first length) and about 50% of the slits can have substantially the
same length (e.g., a second length) and the second length can be
different from the first length. In such an embodiment, each
successive slit 62 on the contact member 52 can be of an
alternating length or any other pattern of lengths as deemed
suitable. In an embodiment in which multiple slits 62 are present,
any width 84 as deemed suitable may separate one slit 62 from the
next successive slit 62. Such width 84 can be recognized as a width
84 of a contact element 54. In an embodiment, the width 84 may
range from about 1, 2, 3, 4, 5, 6 or 7 mm to about 8, 9, 10, 11,
12, 13, 14, or 15 mm.
In an embodiment, the slit(s) 62 can be incorporated into the
contact member 52 when the contact member 52 is in a flat, unfolded
configuration or when the contact member 52 is in a folded
configuration. In an embodiment, the slit 62 can be a cut in the
contact member 52 which fully extend from a first surface 64
through to a second surface 66 of a contact member 52. In an
embodiment, the slit 62 can be a continuous or intermittent cut. In
an embodiment, the slit 62 can be a line of weakness. In an
embodiment, the slit 62 can be linear, arcuate, or combinations
thereof.
FIG. 9A-9E illustrate various embodiments of slits 62 incorporated
into the contact member 52. As shown in the non-limiting examples
of FIG. 9A-9E, the slits 62 can be cut through from a first surface
64 to a second surface 66 of a contact member 52. FIG. 9A provides
a non-limiting example of slits 62 extending from a first edge 98
of contact member 52 towards a second edge 100 of contact member
52. As shown in FIG. 9A, the slits 62 do not extend the entire
length 82 of the contact member 52. Additionally, as illustrated in
FIG. 9A, the slits 62 are cut to extend in a straight line from the
first edge 98 towards the second edge 100 of the contact member 52.
FIG. 9B provides a non-limiting example of slits 62 incorporated
into the contact member 52 and positioned along a centerline 120 of
the contact member 52. The contact member 52 may be folded during
manufacturing, as will be described herein, and a fold 86 can be
formed along the centerline 120 of the contact member 52. After the
folding of the contact member 52, a slit 62 can have two sides
oriented in opposite directions from each other. FIG. 9C provides a
non-limiting example of slits 62 incorporated into a contact member
52 along a centerline 120 of the contact member 52. The slits 62
are illustrated in a chevron pattern. The contact member 52 can be
folded during manufacturing and a fold 86 can be formed along the
centerline 120 of the contact member 52. After the folding of the
contact member 52, a slit 62 can have two sides oriented in the
same direction as each other. FIG. 9D provides a non-limiting
example of slits 62 incorporated into a contact member 52 wherein
the slits 62 are provided in an arcuate manner. In such an
embodiment, the contact member 52 can be manipulated into a folded
configuration such as described herein, however, it is to be
understood that folding is not necessary. As further illustrated in
FIG. 9D in a non-limiting example, at least one row of slit(s) 62
can be provided and in an embodiment, more than one row of slit(s)
62 can be provided. FIG. 9D further provides a non-limiting example
of an edge 98 of the contact member 52 which can be formed with an
undulating arcuate pattern. FIG. 9E provides a non-limiting example
of slits 62 incorporated into a contact member 52 along a
centerline 120 of the contact member 52. The slits 62 are
illustrated in an arcuate manner. The contact member 52 can be
folded during manufacturing and a fold 86 can be formed along the
centerline 120 of the contact member 52. After the folding of the
contact member 52, a slit 62 can have two sides oriented in the
same direction as each other. While the illustrations of FIG. 9A-9E
generally illustrate patterns of slit(s) 62, it is to be understood
that the slit(s) 62 can be symmetrical, asymmetrical, arcuate, or
any other configuration as deemed suitable. While the illustrations
of FIGS. 9B, 9C, and 9E generally illustrate a centerline 120 that
will produce symmetrical sides of the contact member 52 around a
fold 86, it is to be understood that the fold 86 need not always be
positioned at a centerline 120 of the contact member 52. It may be
deemed suitable to place a fold, such as fold 86, offset from the
centerline 120 of the contact member 52. In such an embodiment, one
side of a folded contact member 52 may be longer than the other
side of the folded contact member 52.
FIG. 10A-10C illustrate various embodiments of slits 62
incorporated into a contact member 52 when the contact member 52 is
in a folded configuration. As shown in the non-limiting examples of
FIG. 10A-10C, the slits 62 can be cut through from a first surface
64, through the second surface 66 and to the opposite first surface
64 of the contact member 52. FIG. 10A provides a non-limiting
example of slits 62 extending from a fold 86 in a direction towards
the first and second edges, 98 and 100, of the contact member 52.
As shown in FIG. 10A, the slits 62 do not extend the entire length
of the contact member 52. Additionally, as illustrated in FIG. 10A,
the slits 62 are cut to extend in a straight line from the fold 86
towards the first and second edges, 98 and 100, of the contact
member 52. FIG. 10B provides a non-limiting example of slits
incorporated into a folded contact member 52. The slits 62 are
illustrated as extending at an angle from the fold 86 towards the
first and second edges, 98 and 100, of the contact member 52. FIG.
10C provides a non-limiting example of slits 62 provided in an
arcuate configuration. As illustrated, the slits 62 do not extend
from the fold 86 of the contact member 52.
A slit can have a directional relationship with the longitudinal
axis 16 of a resultant absorbent core 26 of a pledget 12. In an
embodiment, a slit 62 may be incorporated into the contact member
52 in a direction parallel to the longitudinal axis 16 of the
resultant absorbent core 26 of a pledget 12. In an embodiment, a
slit 62 may be incorporated into the contact member 52 in a
direction perpendicular to the longitudinal axis 16 of the
resultant absorbent core 26 of a pledget 12. In an embodiment, a
slit 62 can be incorporated into the contact member 52 in a
direction at an angle to the longitudinal axis 16 of the resultant
absorbent core 26 of a pledget 12. As noted above, a slit 62 can be
incorporated in the contact member 52 in an arcuate
configuration.
In an embodiment, a contact element 54 can have a directional
relationship with the longitudinal axis 16 of the resultant
absorbent core 26 that is substantially similar to the relationship
of a slit 62 to the longitudinal axis 16 of the resultant absorbent
core 26 of the pledget 12. In an embodiment, a contact element 54
of a contact member 52 can be parallel with the longitudinal axis
16 of the resultant absorbent core 26 of the pledget 12. In an
embodiment, a contact element 54 of a contact member 52 can be
perpendicular to the longitudinal axis 16 of the resultant
absorbent core 26 of the pledget 12. In an embodiment, a contact
element 54 of a contact member 52 can be at an angle to the
longitudinal axis 16 of the resultant absorbent core 26 of the
pledget 12. In an embodiment in which a slit 62 can be provided in
an arcuate configuration, a contact element 54 can have any
relationship with the longitudinal axis 16 of the resultant
absorbent core 26 of the pledget 12 as desired.
In an embodiment, the contact member 52 can be aligned on the cover
34 such that the bonded edge 56 of the contact member 52 can be
parallel with the longitudinal axis 16 of the resultant absorbent
core 26 of the pledget 12. In an embodiment, the contact member 52
can be aligned on the cover 34 such that the bonded edge 56 of the
contact member 52 is perpendicular to the longitudinal axis 16 of
the resultant absorbent core 26 of the pledget 12. In an
embodiment, the contact member 52 can be aligned on the cover 34
such that the bonded edge 56 of the contact member 52 can be at an
angle to the longitudinal axis 16 of the resultant absorbent core
26 of the pledget 12. In such an embodiment, the contact member 52
may be configured to spiral around the resultant absorbent core 26
of the pledget 12.
FIGS. 11 through 13 provide non-limiting illustrations of exemplary
embodiments of an absorbent core 26 of a pledget 12 of a tampon 10.
In the non-limiting illustration shown in FIG. 11, the slits 62 and
the contact elements 54 of the contact member 52 are in a direction
parallel to the longitudinal axis 16 of the absorbent core 26 of
the pledget 12. In such an embodiment, the bonded edge 56 can be
perpendicular to the longitudinal axis 16 of the absorbent core 26
of the pledget 12. In the non-limiting illustration shown in FIG.
12, the slits 62 and the contact elements 54 of the contact member
52 are in a direction perpendicular to the longitudinal axis 16 of
the absorbent core 26 of the pledget 12. In such an embodiment, the
bonded edge 56 can be parallel to the longitudinal axis 16 of the
absorbent core 26 of the pledget 12. In the non-limiting
illustration shown in FIG. 13, the slits 62 are provided in an
arcuate configuration and the contact elements 54 of the contact
member 52 are in a direction parallel to the longitudinal axis 16
of the absorbent core 26 of the pledget 12. In the embodiment
illustrated, the bonded edge 56 can be perpendicular to the
longitudinal axis 16 of the absorbent core 26 of the pledget
12.
In an embodiment, the contact member 52 can be bonded to the cover
34 in any location of the cover 34 as deemed suitable. In an
embodiment, the bonded edge 56 of the contact member 52 can be
substantially aligned with an edge, such as edges 42 or 44, of the
cover 34. In an embodiment in which the bonded edge 56 is
perpendicular to the longitudinal axis 16 of the absorbent core 26,
the bonded edge 56 of the contact member 52 can be positioned at
any location along the longitudinal axis 16 of the absorbent core
26 as deemed suitable. In an embodiment, the free edge 58 of the
contact member 52 can be substantially aligned with an edge, such
as edge 42 or 44, of the cover 34. In an embodiment, the free edge
58 of the contact member 52 can extend beyond an edge, 42 or 44, of
the cover 34. In an embodiment, the free edge 58 of the contact
member 52 can extend beyond the insertion end 18 or the withdrawal
end 20 of the pledget 12 of the tampon 10. It is to be understood
that the contact member 52 can extend beyond an edge, 42 or 44, of
the cover 34, beyond the insertion end 18, beyond the withdrawal
end 20 of the pledget 12 of the tampon 10 in any configuration such
as when the contact member 52 is parallel to, perpendicular to, or
at an angle to the longitudinal axis 16 of the absorbent core 26 of
the pledget 12 of the tampon 10.
In an embodiment, at least one contact member 52 is bonded with the
cover 34. In an embodiment, at least 1, 2, 3, 4, or 5 contact
members 52 can be bonded with the cover 34. In an embodiment, the
cover 34 can be bonded to from 1, 2, 3, 4, or 5, to 6, 7, 8, 9, or
10 contact members 52. In an embodiment in which multiple contact
members 52 are present, a contact member 52 can be bonded to the
cover 34, one or more additional contact members 52, itself, or
combinations thereof. In an embodiment in which multiple contact
members 52 are present, a portion of a contact member 52 can
overlap a portion of another contact member 52. For example, a slit
region 70 of one contact member 52 can overlap a bonded region 72,
a free non-slit region 74, a slit region 70, or combinations
thereof of another contact member 52. FIG. 14 provides a
non-limiting illustration of a cover 34 in communication with two
contact members 52 in which a slit region 70 of a first contact
member 52 can overlap a bonded region 72 and a portion of a free
non-slit region 74 of a second contact member 52. In an embodiment,
in which multiple contact members 52 are present, the contact
members 52 can be oriented in the same direction (e.g., the free
edges 58 of each contact member 52 are oriented towards the
insertion end 18), in opposite directions (e.g., a free edge 58 of
one contact member 52 is oriented towards the insertion end 18 and
a free edge 58 of a different contact member 52 is oriented towards
the withdrawal end 20), and combinations thereof.
As illustrated in FIG. 15A, in an embodiment, the contact member 52
can have at least one fold 86. In such an embodiment in which a
fold 86 is present, the contact member 52 can be bent upon itself
such that one surface, 64 or 66, associated with the first edge 98
of the contact member 52 can be in communication with the same
surface, 64 or 66, associated with the second edge 100 of the
contact member 52. As a non-limiting example, as illustrated in
FIG. 15A, the contact member 52 can contain a single fold 86
bringing a first portion 88 of the first surface 64 into
communication with a second portion 90 of the first surface 64. In
the example illustrated in FIG. 15A, the fold 86 can bring a first
edge 98 of the contact member 52 into communication with a second
edge 100 of the contact member 52. In an embodiment, when such a
contact member 52 is bonded to a cover 34, the two edges, 98 and
100, can be contained within the bonded region 72 and the fold 86
can be a free edge 58 of the contact member 52. As discussed above,
the contact member 52 can have at least one slit 62 extending
through the layers, 102 and 104, of the contact member 52. As
discussed above, in an embodiment, the slit 62 can extend from the
free edge 58 (i.e., the fold 86) of the contact member 52 in a
direction toward the bonded region 72 of the contact member 52. The
at least one slit 62 can be incorporated into the contact member 52
prior to or after the contact member 52 has been folded. As
illustrated in FIG. 15B, in an embodiment, the contact member 52
can have at least one fold 86 which can be positioned inward of the
contact member 52 such that the fold 86 can be positioned in the
interior region 108 of the contact member 52. In such an
embodiment, multiple layers of contact elements 54 can overlap each
other.
As illustrated in FIG. 16, in an embodiment, the contact member 52
can have at least two folds 86 and 92. In such an embodiment in
which two folds 86 and 92 are present, the contact member 52 can be
bent upon itself such that a first portion of one surface, 64 or
66, of the contact member 52 can be in communication with a second
portion of the same surface, 64 or 66, and a third portion of one
surface, 64 or 66, of the contact member 52 can be in communication
with a portion of the other surface, 64 or 66. As a non-limiting
example, as illustrated in FIG. 16, the contact member 52 can
contain a first fold 86 bringing a first portion 88 of the first
surface 64 into communication with a second portion 90 of the first
surface 64. The contact member 52 can contain a second fold 92
bringing a third portion 94 of the first surface 64 into
communication with a first portion 96 of the second surface 66. In
the example illustrated in FIG. 16, the fold 86 can bring a first
edge 98 of the contact member 52 into communication with an
interior region 108 of the contact member 52 and the fold 92 can
bring a second edge 100 of the contact member 52 into communication
with the first fold 86. In an embodiment, when such a contact
member 52 is bonded to a cover 34, the first fold 86 and the second
edge 100 can be contained within the bonded region 72 and the
second fold 92 can be a free edge 58 of the contact member 52. In
an embodiment, the contact member 52 can have at least one slit 62
extending through the layers, 102, 104 and 106, of the contact
member 52 and extending from the free edge 58 (i.e., the fold 92)
of the contact member 52 in a direction toward the bonded region 72
of the contact member 52. The at least one slit 62 can be
incorporated into the contact member 52 prior to or after the
contact member 52 has been folded.
FIG. 17 is an illustration of a non-limiting example of a contact
member 52 which can be in communication with an outer sheath 110.
In various embodiments, the outer sheath 110 can be formed from
nonwoven materials or apertured films. The nonwoven materials can
include, but are not limited to, materials such as natural fibers,
synthetic fibers, or blends of natural and synthetic fibers.
Natural fibers include, but are not limited to, rayon, cotton, wood
pulp, flax, and hemp. Synthetic fibers can include, but are not
limited to, fibers such as polyester, polyolefin, nylon,
polypropylene, polyethylene, polyacrylic, vinyl polyacetate,
polyacrylate, cellulose acetate, or bicomponent fibers, such as
bicomponent polyethylene and polypropylene fibers. The outer sheath
110 can be made by any number of suitable techniques such as, for
example, being spunbond, carded, hydroentangled, thermally bonded,
and resin bonded. In an embodiment, the outer sheath 110 can be
formed from an apertured thermoplastic film having either a
two-dimensional or a three-dimensional thickness. In an embodiment,
the outer sheath 110 can be a 12 gsm smooth calendared material
made from bicomponent, polyester sheath and polyethylene core,
fibers such as Sawabond 4189 available from Sandler AG,
Schwarzenbach, Germany. In an embodiment, the outer sheath 110 can
be formed from a single piece of material. In an embodiment, the
outer sheath 110 can be formed from multiple discrete pieces of
material which are bonded together.
In an embodiment in which the contact member 52 is in communication
with an outer sheath 110, the outer sheath 110 can be bonded to the
contact member 52 in any manner such that the outer sheath 110
encloses the contact member 52. For example, FIG. 18 illustrates an
embodiment of a method of bonding an outer sheath 110 to a contact
member 52. FIG. 18 illustrates an outer sheath ribbon 124 in
contact with a contact member ribbon 126. The contact between the
outer sheath ribbon 124 and the contact member ribbon 126 can be
enhanced by bonding the two ribbons, 124 and 126, together by any
method including, but not limited to, adhesives, thermal bonding,
pressure bonding, mechanical entanglement, hydroentanglement,
ultrasonic bonds, microwave bonds, or any other conventional
technique. The contact member ribbon 126 and the outer sheath
ribbon 124 can each be provided with at least one slit 62 in an
area where the two ribbons, 124 and 126, overlap. The incorporation
of the at least one slit 62 can be completed by any manner deemed
suitable such as, for example, knife cutting. The contact member
ribbon 126 and the outer sheath ribbon 124 can be folded either
before or after the incorporation of the at least one slit 62. The
outer sheath ribbon 124 can be folded over the contact member
ribbon 126 to enclose the contact member ribbon 126 within the
outer sheath ribbon 124. It is to be understood that the contact
member ribbon 126 need not be folded and the at least one slit 62
can be incorporated into a folded or un-folded contact member
ribbon 126. Folding the outer sheath ribbon 124, and the contact
member ribbon 126 if desired, can bring the first edge 140 and the
second edge 142 of the outer sheath ribbon 124 into communication
with each other and the two edges, 140 and 142, can be bonded
together in a bond area 128. In an embodiment in which the contact
member ribbon 126 has also been folded, the edges, 98 and 100, of
the contact member ribbon 126 can be brought into communication
with each other as well as, in an embodiment, with the edges, 140
and 142, of the outer sheath ribbon 124 and can be bonded together
in the bond area 128. Following the bonding of the edges, 140 and
142, of the outer sheath ribbon 124, a combination ribbon 144,
having both a contact member ribbon 126 and an outer sheath ribbon
124 can be formed. The combination ribbon 144 can have multiple
interconnected contact members 52 in communication with multiple
interconnected outer sheaths 110. In an embodiment, the
interconnected contact members 52 and outer sheaths 110 can be
connected to each other in a continuous pattern in which
substantially no discrete spacing exists between each combined
contact member 52 and outer sheath 110. In an embodiment, the
interconnected contact members 52 and outer sheaths 110 can be
connected to each other in a discrete pattern in which an area 132
of the combination ribbon 144 exists between each contact member 52
and outer sheath 110 wherein the area 132 of the combined ribbon
144 does not contain at least one slit 62. The combined ribbon 144
can undergo a separation process, such as, but not limited to,
knife cutting, wherein an individual discrete combination 134 of a
contact member 52 having an outer sheath 110 is separated from the
combined ribbon 144. The separation of the discrete contact member
52 and outer sheath 110 from the combined ribbon 144 can occur in
any location along the combined ribbon 144 as desired such as, for
example, in an area 132 in which the combined ribbon 144 does not
contain at least one slit 62.
While FIG. 18 illustrates an embodiment of a method of bonding an
outer sheath ribbon 124 and a contact member ribbon 126, it is to
be understood that a discrete piece of outer sheath 110 material
can be bonded to a discrete piece of contact member 52 material. In
an embodiment, the outer sheath 110 can be bonded to the contact
member 52 prior to or after the contact member 52 has been folded,
if folding of the contact member 52 is desired. In an embodiment,
the outer sheath 110 can enclose a contact member 52 that does not
contain a fold 86. In an embodiment, the outer sheath 110 can be
bonded to the contact member 52 prior to the incorporation of
slit(s) 62 into the contact member 52. In such an embodiment, the
outer sheath 110 and the contact member 52 can both be cut and
provided with corresponding slit(s) 62. In an embodiment in which
the contact member 52 is enclosed by an outer sheath 110, the outer
sheath 110 can have a slit region 112, bonded region 114, and free
non-slit region 116 corresponding to the slit region 70, bonded
region 72, and free non-slit region 74, respectively, of the
contact member 52.
In an embodiment, the combined ribbon 144 can be bonded to a cover
ribbon 136. In an embodiment, a discrete contact member 52, and if
desired a discrete outer sheath 110, can be bonded to a cover
ribbon 136. In an embodiment, a discrete contact member 52, and if
desired a discrete outer sheath 110, can be bonded to a discrete
cover 34. FIG. 19 provides a non-limiting illustration of a method
of bonding a discrete combination 134 of a contact member 52 and
outer sheath 110 to a cover ribbon 136. As illustrated, a cover
ribbon 136 can be provided and at least one discrete combination
134 of a contact member 52 and outer sheath 110 can be bonded to
the cover ribbon 136. The discrete combination 134 of the contact
member 52 and the outer sheath 110 can have a first edge, such as
edge 146, which can be bonded to the cover ribbon 136 by any
suitable method such as, but not limited to, adhesives, thermal
bonding, pressure bonding, mechanical entanglement,
hydroentanglement, ultrasonic bonds, microwave bonds, or any other
conventional technique. The bonding of edge 146 to the cover ribbon
136 can form a bonded edge 56. The discrete combination 134 of the
contact member 52 and the outer sheath 110 can have a second edge,
such as edge 148, which remains unbound from the cover ribbon 136
and can form, therefore, a free edge 58. The cover ribbon 136 can
undergo a separation process, such as, but not limited to, knife
cutting, wherein an individual unit having a cover 34, a contact
member 52 and an outer sheath 110 is separated from the cover
ribbon 136. In such an embodiment, the individual unit of the cover
34, the contact member 52 and the outer sheath 110 can be bonded to
a nonwoven ribbon 32, a fleece 30, a blank 28 or a pledget 12 as
described above.
It is to be understood that, in some embodiments, when the cover 34
and contact member 52 combination are bonded to the nonwoven ribbon
32, the fleece 30, the blank 28, or the pledget 12, a portion of
the free edge 58 of the contact member 52 may become bonded to the
overall structure dependent upon how and where the cover 34 and
contact member 52 combination is bonded to the structure such as
the nonwoven ribbon 32, the fleece 30, the blank 28, or the pledget
12. In such embodiments, at least about 70, 75, 80, 85, 90, or 95%
of the free edge 58 remains free from bonding.
In an embodiment, the cover 34 and the contact member 52 can be
integral with each other. FIG. 20 illustrates such an embodiment in
which the cover 34 can be the contact member 52. In an embodiment,
the cover 34 can extend beyond the insertion end 18, the withdrawal
end 20, or combinations thereof. In such an embodiment, the cover
34 can be provided with at least one slit 62 as described herein.
In an embodiment, the cover 34 can be provided with at least one,
two, three, four, five, six, seven, eight, nine, or ten slits 62.
The cover 34 can have at least one contact element 54 as described
herein. The cover 34 can have as many contact elements 54 as deemed
suitable.
As noted above, the nonwoven ribbon 32 can be separated into
individual units of fleece 30 which can be rolled, stacked, folded
or otherwise manipulated into blanks 28 before compressing the
blanks 28 into pledgets 12. For example, suitable menstrual tampons
may include "cup" shaped pledgets like those disclosed in U.S.
Publication No. 2008/0287902 to Edgett and U.S. Pat. No. 2,330,257
to Bailey; "accordion" or "W-folded" pledgets like those disclosed
in U.S. Pat. No. 6,837,882 to Agyapong; "radially wound" pledgets
like those disclosed in U.S. Pat. No. 6,310,269 to Friese;
"sausage" type or "wad" pledgets like those disclosed in U.S. Pat.
No. 2,464,310 to Harwood; "M-folded" tampon pledgets like those
disclosed in U.S. Pat. No. 6,039,716 to Jessup; "stacked" tampon
pledgets like those disclosed in U.S. 2008/0132868 to Jorgensen; or
"bag" type tampon pledgets like those disclosed in U.S. Pat. No.
3,815,601 to Schaefer.
A suitable method for making "radial wound" pledgets is disclosed
in U.S. Pat. No. 4,816,100 to Friese. The radial winding method can
also include a method for compressing the blank into a pledget like
that disclosed in U.S. Pat. No. 6,310,269 to Friese. Suitable
methods for making "W-folded" pledgets are disclosed in U.S. Pat.
No. 6,740,070 to Agyapong; U.S. Pat. No. 7,677,189 to Kondo; and
U.S. 2010/0114054 to Mueller. A suitable method for making "cup"
pledgets and "stacked" pledgets is disclosed in U.S. 2008/0132868
to Jorgensen.
In various embodiments, the blank 28 can be compressed into a
pledget 12. The compressing step can utilize any suitable means and
apparatus. For example, the compressing step may utilize a
plurality of dies which reciprocate relative to one another so as
to form a mold cavity therebetween. When the blank 28 (e.g., a
softwind) is positioned within the mold cavity, the dies may be
actuated so as to move towards one another and compress the blank
28. The blank 28 may be compressed any suitable amount. For
example, the blank 28 may be compressed at least about 25%, 50%, or
100% of the initial dimensions. For example, a blank 28 can be
reduced in diameter to approximately 1/4 of the original diameter.
The cross-sectional configuration of the resultant pledget 12 may
be circular, ovular, rectangular, hexagonal, or any other suitable
shape.
In various embodiments, the compressing step may not include any
additional heat applied to the pledget 12. In other words, the
blank 28 can be compressed into a pledget 12 without external heat
being applied to the compression equipment or the blank 28. In
various embodiments, the compressing step may incorporate or may be
followed by one or more additional stabilization steps. This
secondary stabilization can serve to maintain the compressed shape
of the pledget 12. In general, the secondary stabilization step can
create hydrogen bonds between the absorbent fibers and/or may
further strengthen the entanglement of the absorbent fibers to
maintain the shape of the compressed pledget 12.
In various embodiments, the pledgets 12 may be subject to further
processing to result in a finished tampon. For example, the
pledgets 12 may be joined with a withdrawal aid 14 and/or
applicator.
The withdrawal aid 14 may be attached to the pledget 12 in any
suitable manner. For example, an opening can be formed through the
pledget 12 (and cover 34 if provided) so as to provide a means for
attaching a withdrawal aid 14. In various embodiments, the
withdrawal aid 14 can be attached to the fibrous material 138
before or after it is compressed into the pledget 12. The
withdrawal aid 14 can be attached to the fibrous material 138 and
then looped upon itself. A knot 118 can then be formed near the
free ends of the withdrawal aid 14 to assure that the withdrawal
aid 14 does not separate from the fibrous material 138. The knot
118 can also serve to prevent fraying of the withdrawal aid 14 and
to provide a place or point where a woman can grasp the withdrawal
aid 14 when she is ready to remove the tampon 10 from her
vagina.
The withdrawal aid 14 can be constructed from various types of
threads or ribbons. A thread or ribbon can be made from 100% cotton
fibers and/or other materials in whole or part. The withdrawal aid
14 can be bonded to the absorbent fibers with or without tying. The
withdrawal aid 14 can have any suitable length and/or the
withdrawal aid 14 can be dyed and/or treated with an anti-wicking
agent, such as wax, before being secured to the pledget 12.
In various embodiments, the tampon 10 may also include one or more
additional features. For example, the tampon 10 may include a
"protection" feature as exemplified by U.S. Pat. No. 6,840,927 to
Hasse, U.S. 2004/0019317 to Takagi, U.S. Pat. No. 2,123,750 to
Schulz, and the like. In some embodiments, the tampon 10 may
include an "anatomical" shape as exemplified by U.S. Pat. No.
5,370,633 to Villalta, an "expansion" feature as exemplified by
U.S. Pat. No. 7,387,622 to Pauley, an "acquisition" feature as
exemplified by U.S. 2005/0256484 to Chase, an "insertion" feature
as exemplified by U.S. Pat. No. 2,112,021 to Harris, a "placement"
feature as exemplified by U.S. Pat. No. 3,037,506 to Penska, or a
"removal" feature as exemplified by U.S. Pat. No. 6,142,984 to
Brown.
In the interests of brevity and conciseness, any ranges of values
set forth in this disclosure contemplate all values within the
range and are to be construed as support for claims reciting any
sub-ranges having endpoints which are whole number values within
the specified range in question. By way of hypothetical example, a
disclosure of a range of from 1 to 5 shall be considered to support
claims to any of the following ranges: 1 to 5; 1 to 4; 1 to 3; 1 to
2; 2 to 5; 2 to 4; 2 to 3; 3 to 5; 3 to 4; and 4 to 5.
The dimensions and values disclosed herein are not to be understood
as being strictly limited to the exact numerical values recited.
Instead, unless otherwise specified, each such dimension is
intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
All documents cited in the Detailed Description are, in relevant
part, incorporated herein by reference; the citation of any
document is not to be construed as an admission that it is prior
art with respect to the present invention. To the extent that any
meaning or definition of a term in this written document conflicts
with any meaning or definition of the term in a document
incorporated by references, the meaning or definition assigned to
the term in this written document shall govern.
While particular embodiments of the present invention have been
illustrated and described, it would be obvious to those skilled in
the art that various other changes and modifications can be made
without departing from the spirit and scope of the invention. It is
therefore intended to cover in the appended claims all such changes
and modifications that are within the scope of this invention.
* * * * *